Assessor Resource

MEM04005C
Produce moulds and cores by hand (jobbing)

Assessment tool

Version 1.0
Issue Date: May 2024


This unit of competency applies to the production of sand moulds and cores by a foundry tradesperson often called a moulder using manual (jobbing) methods to produce metal castings. The unit does not cover machine moulding. The jobbing moulding methods covered by this unit apply to a range of materials and types of patterns and require matching of job specifications and patterns to mould and core production based on knowledge of the metal casting process.

This unit has been developed for Engineering Tradesperson - Fabrication apprenticeship training and the recognition of trade level skills in the production of moulds and cores. The ability to match patterns, moulds and cores for a wide range of jobs is a key trade skill and can usually only be gained from experience in the range of work and the combination of on and off-the-job training typical of an apprenticeship.

Where lifting and moving moulds and cores requires the use of mobile load shifting equipment or overhead cranes, appropriate manual handling units should also be selected. Where the securing of moulds requires welding skills, refer to MEM05012C Perform routine manual metal arc welding and MEM05050B Perform routine gas metal arc welding, as appropriate.

Band: A

Unit Weight: 16

This unit of competency covers manual making (jobbing) of sand moulds and cores for metal casting typically in a working foundry. Moulds are made by an Engineering Tradesperson - Fabrication from specifications, instructions or drawings.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Prerequisites

Path 1

MEM09002B

Interpret technical drawing

MEM18001C

Use hand tools

Employability Skills

This unit contains employability skills.



Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

A person who demonstrates competency in this unit must be able to produce a range of jobbing moulds and cores by hand. Competency in this unit cannot be claimed until all prerequisites have been satisfied.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Assessors must be satisfied that the candidate can competently and consistently apply the skills covered in this unit of competency in new and different situations and contexts. Critical aspects of assessment and evidence include:

following all safety procedures for working safely in a typical working foundry environment

knowledge of the casting process including the role of patterns, sands, moulds and cores, and the importance of correct methoding

matching of specifications, sketches and drawings to mould and core requirements for a range of patterns, metals and sands

planning skills are evident in sequence of work, selection and layout of materials, and construction of moulds and cores

appropriately identifying, assembling and determining patterns as fit for purpose

ensuring core positioning is in accordance with job specifications

placing methoding components in accordance with job specifications

selecting moulding equipment and media to match a range of job requirements

making moulds, cores and pouring basins for a range of jobs and metals efficiently and to meet all safety requirements with minimum waste of materials

disposing of used sand and debris according to standard operating procedures and regulations.

Context of and specific resources for assessment

This unit has been developed to support training in and recognition of trade level jobbing moulding skills as applied to a jobbing moulding environment.

Assessment resources include a furnace to supply adequate molten metal for testing of moulds and cores, sand and other materials to enable enough sufficient moulds and cores to be produced and all normal foundry safety and personal protective equipment.

The competencies covered by this unit would be demonstrated by an individual working alone or as part of a team. The assessment environment should not disadvantage the candidate.

Method of assessment

The emphasis for assessment should be on jobbing ability, that is, the ability to produce moulds and cores for a variety of job specifications involving different metals, sands and patterns.

A single assessment event is not appropriate. On the job assessment should be included as part of the assessment process wherever possible. Where assessment occurs off the job, judgement must consider evidence of the candidate's performance in a productive work environment that includes a sufficient range of appropriate tasks and materials to cover the scope of application for this unit.

Assessors should gather a range of evidence that is valid, sufficient, current and authentic. Evidence can be gathered through a variety of ways including direct observation, supervisor's reports, project work, samples and questioning. Questioning techniques should not require language, literacy and numeracy skills beyond those required in this unit of competency.

The candidate must have access to all tools, equipment, materials and documentation required. The candidate must be permitted to refer to any relevant workplace procedures, product and manufacturing specifications, codes, standards, manuals and reference materials.

Guidance information for assessment

This unit could be assessed in conjunction with any other units addressing the safety, quality, communication, materials handling, recording and reporting associated with producing jobbing moulds and cores by hand or other units requiring the exercise of the skills and knowledge covered by this unit.

Assessors must be satisfied that the candidate can competently and consistently perform all elements of the unit as specified by the criteria, including required knowledge, and be capable of applying the competency in new and different situations and contexts.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Required skills

Required skills include:

interpreting written instructions, sketches and drawings

assembling and positioning patterns in moulding boxes

positioning ancillary methoding components

preparing moulding media

filling and compacting mould assemblies

stripping patterns

inspecting moulds

finishing moulds

positioning cores in prints

closing moulds

placing pouring basins

securing moulds

following oral instructions

entering routine and familiar information onto proforma and standard workplace forms

Required knowledge

Required knowledge includes:

metal casting process

variety of pattern types and their application in a casting process

pattern assembly techniques

selection of a moulding box to match job and pattern

principles and processes for selection of ancillary components

sand types and their bonding systems

compaction processes

parting and stripping systems

mould requirements including vents, runners, risers and other methoding requirements

finishing and closing techniques

core placement

pouring requirements

securing systems

pattern care and storage

environmental requirements

use and application of personal protective equipment

foundry safe work practices and procedures

hazards and control measures associated with producing moulds and cores by hand (jobbing)

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Materials

Materials may include:

binders

hardeners

sand additives

mould coatings

Patterns

Patterns may include:

flatback

uneven

plated patterns

multi-joint

consumable

split patterns

loose piece patterns

patterns requiring odd sides

cored moulds

drag and cope mould

Moulds

Moulds may include:

flatback

uneven jointed

multi-part moulds

Cores

Cores may include full, half and segment cores

Mould securing methods

Mould securing methods may include:

weights

clamps

bolting

Moulding media

Moulding media may include use of a wide range of sands including green sand, shell sand and chemically bonded media

Pouring basins

Pouring basins may include hand and pattern formed

Parting and stripping systems

Parting and stripping systems may include dry and wet

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Job requirements are correctly identified from drawings, instructions and specifications 
Material is selected appropriate to job requirements 
Sequence of operation including job set up is determined for maximum safety, efficiency and to meet job specifications 
Pattern equipment is correctly identified from specifications to standard operating procedures 
Pattern equipment is inspected to specifications, and damaged patterns are identified for repair or replacement to standard operating procedures 
Pattern is assembled to specification 
Pattern equipment is set up to specification according to standard operating procedures 
Core is positioned in prints utilising chaplets and chills as required and vented to specification according to standard operating procedures 
Mould is closed and checked for compliance to component specification in accordance with standard operating procedures 
Appropriate moulding/core making equipment is selected and positioned according to standard operating procedures 
Appropriate moulding media is selected to produce mould and core to specification 
Mould is secured according to standard operating procedures 
Moulding media is used to produce mould and core according to standard operating procedures 
Pouring basin is selected or manufactured to specification and positioned in accordance with standard operating procedures 
Mould and cores are rammed up with joints and drawbacks as required to standard operating procedures 
Parting and stripping systems are utilised in accordance with standard operating procedures 
Loose pieces, vents, risers and runners are positioned and secured as required to standard operating procedures 
Pattern and loose pieces are removed from mould and core box in a safe manner least likely to cause damage to the pattern and in accordance with standard operating procedures 
Mould is inspected and repaired as required 
Mould and core is cleaned and painted according to specification using standard operating procedures 
All materials/debris is cleared and work site cleaned and left in a safe state 
Unwanted treated sand is disposed of according to standard operating procedures and legislative and statutory requirements 

Forms

Assessment Cover Sheet

MEM04005C - Produce moulds and cores by hand (jobbing)
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MEM04005C - Produce moulds and cores by hand (jobbing)

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: